JPH079132B2 - Door manufacturing method - Google Patents

Description

Detailed Description of the Invention [Industrial applications]

The present invention relates to an improvement in a method of manufacturing a door having a structure in which surface plates are provided on both sides of a frame material.

[Prior art]

The door can be made beautiful by decorating the surface. The simplest surface decoration is a paint finish. However, the surface finish with a paint is planar and has the drawback that it does not give a three-dimensional, high-quality surface finish. As a door having a three-dimensional surface finish, a door formed by pressing a metal surface plate is disclosed in the following publication. The steel plate door disclosed in the official gazette of Japanese Utility Model Publication No. 55-33018 has a printed surface pattern made of metal such as a wood grain pattern, and a V groove is formed in accordance with this design. That is, this steel plate door has a printed design,
It is three-dimensionally decorated with a V groove. The door disclosed in the above publication is manufactured by fixing a plurality of decorative panels, which are three-dimensionally press-molded, to the opening of the surface plate. The door obtained by this manufacturing method has a decorative panel on the surface of which is a three-dimensional decorative pattern.

[Problems to be Solved by the Invention]

The doors disclosed in these publications have three-dimensional unevenness on the surface plate by press molding. However, the door having this structure has a drawback that the manufacturing cost becomes high when a small amount of a wide variety of products is manufactured because the surface plate needs to be press-molded in the manufacturing process. That is because different patterns require different press molds. Furthermore, when a pattern such as a pattern is printed and press-molded in accordance with the pattern, extremely high positioning accuracy is required between the pattern and the uneven position formed by the press molding. It has the drawback of being significantly reduced. Therefore, the door having a three-dimensional pattern with this structure has a low production efficiency in high-mix low-volume production, and has a drawback that the unit price rises when the production quantity of a single lot is small. The present inventor has managed to investigate various three-dimensional surface decoration techniques in order to solve this drawback. As a result, we found a unique three-dimensional pattern used for surface decoration of wooden products. The three-dimensional decoration is to slice a shell into thin pieces, cut the shells into various patterns, and stretch the shells on the surface of a wooden product in a certain arrangement. The three-dimensional decorative pattern of this structure can be made into various three-dimensional patterns by changing the pattern on the surface plate. Therefore, it is most suitable for decorating doors that are produced in small quantities in many types, and the pattern on the surface can be changed to easily change the pattern on the surface plate. In order to apply this technology to doors, we have prototyped doors with various patterns. For the door, the shell used for the design was changed to a veneer sliced from thin wood or a metal plate. This is because the design matches the purpose of the door. The veneer plate and the metal plate were cut into a predetermined shape with a blade to form a decorative pattern member having a beautiful pattern or character. The decorative pattern member was adhered to the door face plate via an adhesive material. Further, a transparent paint was applied on the surface. The transparent surface paint exposes the design of the decorative pattern member to the outside and cleanly finishes the surface plate and the decorative pattern member. If you make a door this way,
It is possible to realize a high-grade door with a three-dimensional effect that is difficult to obtain with conventional doors. Further, by adjusting the material of the decorative pattern member and the material of the surface plate to change the color and pattern, and further cutting the decorative pattern member into various shapes, doors of various designs can be manufactured. However, when the door is manufactured by this method, it takes a great deal of time to finish the outer periphery of the decorative pattern member neatly,
There was a drawback that productivity was low. This is because the glue 6 stains the outer periphery of the decorative pattern member 4 as shown in FIG. 3 when the decorative pattern member is bonded to the surface plate. That is, the decorative pattern member 4 is adhered to the surface plate 1 in the following steps. The glue 6 is applied to the back surface of the decorative pattern member 4. The decorative pattern member 4 is pressed and adhered to the surface plate 1. When the decorative pattern member 4 is adhered to the surface plate 1 in this state, when the decorative pattern member 4 is pressed against the surface plate 1, the glue 6 applied to the back surface is pushed out to the outer periphery, and this is projected from the surface of the decorative pattern member. The reason for this is that a step is created by making a step in the transparent surface paint applied to the surface. If the pressing force of the decorative pattern member 4 is weakened or the amount of the glue 6 used is reduced, the stain on the outer periphery of the decorative pattern member can be reduced. However, if the decorative pattern member is not sufficiently pressed, the entire surface of the decorative pattern member cannot be reliably bonded to the surface plate. Even if the amount of glue used is reduced, the decorative pattern member cannot be firmly adhered to the surface plate. A decorative pattern member that is not firmly adhered is likely to be peeled off during use, and the durability of the product is significantly reduced. In particular, when the decorative pattern member and the surface plate are made of different materials, they are easily peeled off. This is because the surface plate and the decorative pattern member have different physical properties such as coefficient of thermal expansion. Doors are used in harsh environments. In particular, the entrance door, which is the main use of the door of the present invention, is required to be used for an environment where external conditions such as temperature and humidity are severe and to keep its beauty for a long time. Durability and beauty are extremely important for a door. This invention was developed for the purpose of solving the drawbacks of the conventional manufacturing method, and the important object of this invention is to
An object of the present invention is to provide a method capable of manufacturing a high-quality door easily, easily and efficiently.

[Means for Solving the Problems]

A door manufacturing method according to the present invention is directed to a rectangular frame member 2
And a surface plate 1 fixed to both sides of the frame member 2, and a method for manufacturing a door. The door manufacturing method of the present invention is characterized by comprising the following steps (a) to (e). (A) A step of adhering a double-sided tape 3 having pressure-sensitive adhesive layers 3A on both sides to the back surface of a decorative plate which is a material different from that of the surface plate 1. However, in this specification, "a decorative plate which is a material different from the surface plate 1" means not only a case where the surface plate 1 and the decorative plate are different materials, for example, a metal plate and a wooden plate, It also includes dissimilar metals such as iron and stainless steel, or dissimilar wood such as cedar and Karaki. Therefore, the surface plate 1 is an iron plate and a stainless plate is used as a decorative plate, or
It is also possible to use Japanese cedar and use a veneered veneer for the decorative board. (B) A step of cutting the decorative plate with the double-sided tape 3 attached. In this step, the double-sided tape 3 and the decorative plate are cut into the same shape. (C) A step of heating the outer periphery of the cut double-sided tape 3. This step does not necessarily have to be a separate step from the step of cutting the decorative plate. The outer peripheral heat treatment of the double-sided tape 3 can also be performed in the step of cutting the double-sided tape 3. (D) A step of attaching the decorative pattern member 4 to the surface of the decorative pattern member 4 with the double-sided tape 3. (E) A step of applying a transparent paint to the surface plate 1 to which the decorative pattern member 4 is adhered, and coating the surfaces of the surface plate 1 and the decorative member with the transparent surface paint 5.

[Operation effect]

In the door manufacturing method according to the present invention, the decorative pattern member 4 is bonded to the surface plate 1 with the double-sided tape 3. Further, with the double-sided tape 3 adhered to the back of the decorative plate, the decorative plate and the double-sided tape 3 are cut together into the same shape. Furthermore, the outer periphery of the double-sided tape 3 is cured by heating, and the decorative pattern member 4 is bonded to the surface plate 1 in this state. According to this method, the decorative pattern member can be simply and easily adhered to the decorative pattern member neatly without squeezing the glue to the outer periphery of the decorative pattern member. This is because the double-sided tape does not stick out from the decorative pattern member even when the decorative pattern member is strongly pressed against the front plate, and the entire back surface of the decorative pattern member can be bonded to the front plate with the double-sided tape. That is, the double-sided tape, the outer periphery of which is hardened by heat, acts as a barrier wall which prevents the hardened portion from protruding when pressed, and the pressure-sensitive adhesive layer is more likely to stick out when pressed than uncured adhesive. There are few, and it has the feature that decorative pattern members can be neatly bonded. Therefore, according to the method of the present invention, three-dimensional doors can be efficiently mass-produced and the manufactured doors can be finished neatly. Furthermore, the manufacturing method of the present invention can adhere the entire surface of the decorative pattern member to the surface plate, and moreover, the decorative pattern member can be strongly pressed against the surface plate to ensure reliable adhesion.
There is a feature that the decorative pattern member can be prevented from peeling off during use and a durable door that can beautifully retain the pattern by the decorative pattern member for a long period of time can be obtained. Furthermore, the manufacturing method of the present invention has a feature that the pattern can be easily changed by changing the shape of the decorative pattern member, and doors with various patterns can be produced at low cost in high-mix low-volume production. Especially, in recent years, it is possible to use a cutting device for cutting a decorative plate and a double-sided tape into a predetermined shape by inputting a figure or a character into a computer by CAD without using an expensive press die. By using this cutting device, decorative pattern members having various patterns can be easily cut, and doors decorated with various patterns and characters can be efficiently produced in a short time.

Embodiments of the present invention will be described below with reference to the drawings. However, the examples shown below exemplify doors for embodying the technical idea of the present invention, and the door manufacturing method of the present invention does not set the conditions of the processing steps as follows. . The door manufacturing method of the present invention can be modified in various ways according to the scope of the claims. Further, in this specification, for easy understanding of the claims, the numbers corresponding to the members shown in the embodiments are referred to as "a range of claims" and "for solving the conventional problems. It is added to the members shown in "Means column" and "Function and effect column". However, the members shown in the claims are not limited to the members of the embodiment. The door shown in FIG. 2 is manufactured by fixing metal surface plates 1 on both sides of a frame member 2 connected in a rectangular shape. The surface plate 1 is manufactured by the following steps. A double-sided tape 3 having pressure-sensitive adhesive layers 3A on both sides is attached to the back surface of the decorative plate. The decorative plate is cut with the double-sided tape 3 attached. In this step, the double-sided tape 3 and the decorative plate are cut into the same shape. The outer periphery of the cut double-sided tape 3 is heated to cure the outer periphery. The decorative pattern member 4 with the double-sided tape 3 on the surface plate 1
Adhere to the surface of. A transparent paint is applied to the surface plate 1 to which the decorative pattern member 4 is adhered, and the surfaces of the surface plate 1 and the decorative member are covered with the transparent surface paint 5. FIG. 1 shows an enlarged cross-sectional shape of the face plate 1 manufactured in the steps of. As shown in this figure, a decorative pattern member 4 is adhered to the surface of the face plate 1. The decorative pattern member 4 is cut into a shape of a pattern or a character, and the surface plate 1 is stretched to decorate the surface plate 1. The decorative pattern member 4 is used to beautifully decorate the surface plate 1.
A decorative plate made of a material different from that of the surface plate 1 is used. Therefore, when the metal plate is used for the surface plate 1, the decorative pattern member 4 uses a metal plate different from the surface plate 1. For example, when an iron plate is used for the surface plate 1, a metal plate made of stainless steel, aluminum, copper, brass or the like is used for the decorative pattern member 4. Further, the decorative pattern member 4 may be a plate material whose surface is plated with metal. The metal-plated plate material has a metal plating layer made of a metal different from that of the surface plate 1,
It can have a different color pattern. When a metal plate is used for the surface plate 1, a veneer sliced from thin wood, a synthetic resin sheet, a cloth, or a sheet material in which these are laminated can be used for the decorative pattern member 4. Furthermore, when a plate material is used for the surface plate 1, a veneer sliced from wood of a different type from the surface plate 1, a synthetic resin sheet, cloth, paper, or a laminated sheet of these is used for the decorative pattern member 4. it can. The decorative plate used as the decorative pattern member 4 has, for example, a thickness of 0.1
Use a plate or sheet material that is ~ 5 mm. Before cutting the decorative plate into the decorative pattern member 4, the double-sided tape 3 is adhered to the entire back surface. The double-sided tape 3 removes the release sheet and adheres to the back surface of the decorative plate. Double-sided tape 3
For this, a base sheet 3B provided with pressure sensitive adhesive layers 3A on both sides is used. Paper or cloth can be used for the base sheet 3B.
Further, as the pressure-sensitive adhesive layer 3A, any material having adhesiveness and capable of adhering the decorative pattern member 4 to the surface plate 1 when pressed can be used. By the way, the process of cutting the decorative plate and the double-sided tape 3 and heating the outer periphery of the double-sided tape 3 is roughly divided into two methods. The first method is to cut the decorative plate and the double-sided tape 3 together and then heat the outer periphery of the double-sided tape 3 to cure it. In this method, the decorative plate and the double-sided tape 3 are cut with a cutter, and then the outer periphery of the double-sided tape 3 is heated and cured. For heating the outer circumference of the double-sided tape 3, a flame of gas focused in an extremely thin beam or a plate-shaped heater can be used. The gas flame is moved along the outer circumference of the double-sided tape 3 to heat and harden the outer circumference. This method has a feature that the outer circumference of the double-sided tape 3 having a complicated curvature shape with a small radius of curvature can be heated. The plate heater heats the surface temperature to, for example, 180 ° C to 300 ° C. The outer surface of the double-sided tape 3 is lightly pressed against the heated surface to heat the outer circumference of the double-sided tape 3. This method is characterized in that the double-sided tape 3 can be heated without controlling the heating temperature and burning the outer periphery of the cut decorative pattern member 4. The second method is a method of simultaneously cutting the decorative plate and the double-sided tape 3 and heating the outer circumference. In this method, the cutting and heating methods differ depending on the type of decorative plate. When the decorative plate is a wood veneer, cloth, synthetic resin sheet, paper, or a laminated material of these, a finely focused flame can be used. The flame burns and cuts the decorative plate and the double-sided tape 3 and heats the outer periphery of the double-sided tape 3 to cure it. When a metal plate or a thermosetting synthetic resin plate that cannot be easily cut by heat is used for the decorative plate, the decorative plate and the double-sided tape 3 are cut with a focused laser beam. The laser beam cuts the decorative plate and the double-sided tape 3 and heats the cutting edge of the double-sided tape 3 to cure it. The laser beam can be converged extremely finely to cut the decorative plate and the double-sided tape 3.
Therefore, there is a feature that the decorative plate and the double-sided tape 3 can be cut as a clean edge. Further, the laser beam has a feature that it can neatly cut not only metal plates but also decorative plates made of almost any material. The decorative pattern member 4, which is cut and the outer periphery of the double-sided tape 3 is heated and cured, peels off the release paper on the surface and attaches the decorative pattern member 4 to the surface plate 1. In other words, the double-sided tape 3 is cut together with the decorative plate while the release paper is stretched, and the outer circumference of the double-sided tape 3 is heated. After this step is completed, the release paper is removed and the decorative pattern member 4 is bonded to the surface plate 1. The surface plate 1 to which the decorative pattern member 4 is adhered has a transparent surface coating applied on its surface. The surface coating is, as shown in Fig. 1,
It is applied to the entire surface of the decorative pattern member 4 and the exposed surface of the surface plate 1.
The surface paint is transparent so that the decorative pattern member 4 can be seen from the outside. Therefore, in this specification, that the surface paint is transparent means that the surface paint is
It means that the decorative pattern member 4 is visible from the outside.

[Brief description of drawings]

FIG. 1 is an enlarged sectional view showing a surface plate of a door manufactured by the method of the present invention, FIG. 2 is a sectional view showing a door manufactured by the method of the present invention, and FIG. 3 is a decorative pattern by a conventional method. It is an expanded sectional view showing the state where a member was bonded to a surface board. 1 ... Front plate, 2 ... Frame material, 3 ... Double-sided tape, 3A ... Pressure-sensitive adhesive layer, 3B ... Base sheet, 4 ... Decorative pattern member, 5 ... Transparent surface paint, 6 ... paste.

Claims (1)

[Claims] 1. A method of manufacturing a door, comprising a rectangular frame member 2 and surface plates 1 fixed on both sides of the frame member 2. The steps (a) to (e) below: A method of manufacturing a door, comprising: (A) A step of adhering a double-sided tape 3 having pressure-sensitive adhesive layers 3A on both sides to the back surface of a decorative plate which is a material different from that of the surface plate 1. (B) A step of cutting the decorative plate into the decorative pattern member 4 with the double-sided tape 3 attached. In this step, the double-sided tape 3 and the decorative plate are cut into the same shape. (C) A step of heating the outer periphery of the cut double-sided tape 3. (D) A step of attaching the decorative pattern member 4 to the surface of the face plate 1 with the double-sided tape 3. (E) A step of applying a transparent paint to the surface plate 1 to which the decorative pattern member 4 is adhered and coating the surfaces of the surface plate 1 and the decorative pattern member 4 with the transparent surface paint 5.